Cover fabric and a method of manufacturing a vehicle seat cover fabric

Abstract

A method of manufacturing a cover for a vehicle seat by weaving a first layer including a synthetic material, weaving a second layer including wool, and interweaving the first layer and the second layer with the second layer underling the first layer. The cover may include a woven top layer and a woven bottom layer, interwoven with the woven top layer. The woven top layer may include a plurality of first warp yarns and a plurality of first weft yarns. The woven bottom layer may include a plurality of second warp yarns and a plurality of second weft yarns. The plurality of second warp and weft yarns may include wool.

What is claimed is: 
     
       1. A method of manufacturing a cover for a vehicle seat comprising:
 weaving a first layer forming an external surface of the vehicle seat that is attached to the seat to be contacted by an occupant positioned on the seat consisting of a synthetic material; 
 weaving a second layer opposite the external surface of the top layer, the bottom layer including wool; and 
 interweaving the first layer and the second layer such that the second layer underlies the first layer, wherein the second layer absorbs moisture from the first layer, and wherein the first layer and the second layer are interwoven with a portion of the yarn of the second layer extending into the first layer. 
 
     
     
       2. The method of  claim 1  wherein weaving the first layer and weaving the second layer are performed simultaneously. 
     
     
       3. The method of  claim 1  wherein the first layer consists of synthetic materials. 
     
     
       4. The method of  claim 1  wherein the second layer includes wool. 
     
     
       5. The method of  claim 1 , wherein the second layer has a moisture absorption rate that is at least 40% greater than the moisture absorption rate of the first layer. 
     
     
       6. The method of  claim 1 , wherein the second layer has a moisture absorption rate of at least 8%. 
     
     
       7. The method of  claim 1 , wherein the first layer comprises a plurality of first warp yarns and a plurality of first weft yarns, arranged orthogonally to the plurality of first warp yarns, and the second layer comprises a plurality of second warp yarns and a plurality of second weft yarns, arranged orthogonally to the plurality of second warp yarns. 
     
     
       8. The method of  claim 7  wherein the plurality of first warp yarns and the plurality of first weft yarns are arranged to be adjacent to an occupant when the cover is mounted on the vehicle seat and the occupant is positioned on the vehicle seat. 
     
     
       9. The method of  claim 7  wherein the first layer comprises a series of microfiber threads. 
     
     
       10. A woven fabric comprising:
 an outer layer including a first set of yarns and a second set of yarns, wherein the first set of yarns and the second set of yarns consist essentially of a synthetic material the outer layer forming an external surface of a seat that is attached to the seat to the seat to be contacted by an occupant of the seat; and 
 an inner layer underlying the outer layer and including a third set of yarns and a fourth set of yarns, wherein the outer layer and the inner layer are interwoven with one another, and wherein the third set of yarns and the fourth set of yarns each comprise wool, wherein the inner layer absorbs moisture from the outer layer, and wherein the outer layer and the inner layer are interwoven with a portion of the yarn of the inner layer extending into the outer layer. 
 
     
     
       11. The woven fabric of  claim 10 , wherein the first set of yarns are arranged along a first direction and the second set of yarns are arranged along a second direction and wherein the third set of yarns are arranged along a third direction and the fourth set of yarns are arranged along a fourth direction. 
     
     
       12. The woven fabric of  claim 11 , wherein the second direction is orthogonal to the first direction. 
     
     
       13. The woven fabric of  claim 11 , wherein the fourth direction is orthogonal to the third direction. 
     
     
       14. The woven fabric of  claim 11 , wherein the first set of yarns and the second set of yarns are arranged to be adjacent to an occupant when the woven fabric is mounted on a vehicle seat and the occupant is positioned on the vehicle seat. 
     
     
       15. The woven fabric of  claim 11 , wherein the third set of yarns and the fourth set of yarns comprise at least 1% wool material by weight. 
     
     
       16. The woven fabric of  claim 11 , wherein the first set of yarns and the second set of yarns each comprise at least 10% polyester material by weight. 
     
     
       17. The woven fabric of  claim 11 , wherein the third set of yarns and the fourth set of yarns have a moisture absorption rate that is at least 40% greater than the moisture absorption rate of the first set of yarns and the second set of yarns. 
     
     
       18. The woven fabric of  claim 10 , wherein the first set of yarns and the second set of yarns have a fiber thickness less than 8 denier.